FACILITIES


Our Facilities

Our manufacturing facilities are equipped with advanced machinery and technology, which will help in producing high-quality products. Having a team of highly competent technicians is also a valuable asset for any manufacturing company, and it's good to know that you have such a team in place. It's also impressive that we manufacture our products according to industry standards, which is a critical factor in ensuring the reliability and safety of the products.

Wire Drawing Process

Wire drawing is a metalworking process used to reduce the cross-section of a wire by pulling the wire through a single, or series of, drawing die(s). Wire drawing is a deformation process in which the cylindrical bar or rod workpiece is pulled through a converging die. However, the material is subjected to compressive stress within the die thereby deforming plastically. A rod is drawn down in order to reduce its diameter. In general, drawing results in a reduction in the area of the cross-section. Drawn rods are used as raw materials for making bolts etc. Wire drawing is usually done in multiple steps, using 4 to 12 dies, because the length of the wire drawn is very large-several meters.

Cold working by wire drawing gives advantages in size accuracy, straightness, and increased mechanical properties when compared to its hot drawing counterpart. Cold Drawn wire exhibits a bright and almost polished finish and will have improved machining characteristics making it ideal for production.

  • Spheroidizing Annealing Process :

In this process, pearlite, the raw material (wire rod) structure, is converted into a stable spherical carbide to lower its strengths and expand its ductility, thus improving transmutability during cold forging.

  • Drawing Process :

In this process, the pickled and coated material is passed through dies to draw wire with the required wire diameters. In this process, the pearlite structure is segmented through cold processing to facilitate spheroidizing during annealing and to adjust wire drawing reduction ratios to meet the required machine properties after wire drawing.

Pelican Engitech utilizes cutting-edge technology. Throughout the operation, advanced computerization programming is used (including CAD and Statistical Process Control). Simulation software is used by engineering to improve tooling life and run-time efficiency for each part.

The Cold Forging Process(Bolt)

Cold forging is often used in the production of high-strength, complex-shaped metal parts for a variety of applications such as automotive, aerospace, and medical industries. Compared to other manufacturing processes like casting, machining or heat treatment, cold forging can provide several benefits, including higher productivity, better material utilization, improved mechanical properties of the finished part, and reduced energy consumption.

Some other key advantages of the cold forming process can include a higher dimensional accuracy than with forged parts, excellent surface quality, and no need to apply additional energy into the process such as extreme temperatures.

Secondary Operations

EBRO supplies efficient turn-key products for our customers by handling all the secondary operations. We recognized the need to customize parts or modify standards to meet our customer’s needs. We can take your secondary headaches away due to our in-house operations. Secondary Operations such as Grinding, Polishing, Tapping, Counter boring, Cutoffs, Drilling / Milling / Slotting / Thread Rolling / Cutting, Thread Locking / Chasing and Others (As per Customer Drawing) can be carried out.

The Cold Forging Process(Nut)

The six-station cold heading machine for nut production. These machines can produce nuts with improved mechanical properties, high quality and at a relatively low production cost. The increased positioning capabilities of the machine allow for the production of both low and high nuts, as well as nuts with reduced turnkey size. Additionally, the machine provides the ability to produce special products, which can help us to expand our product range.

Hexagon Nuts are mass manufactured using a similar multi-station cold former that twists the fastener over between forging stations to allow forging of both faces of the nut. Nut formers or nut formers are the names given to these machines. The last blow on a nut former is to puncture a hole in preparation for the nut to be tapped with an internal thread later.

Threading Process

Roll threading is a cold-forming process that is commonly used to produce threads on bolts. In this process, a set of hardened steel dies are used to form the threads onto the bolt by extending into the outer diameter of the blank bolt. It is important to note that threading is often performed before heat treatment while the steel is still soft, either by rolling or cutting. This is because the steel is easier to work with in its soft state, and it allows for more precise and accurate threading.

Hardening Process

EBRO Fastener operates in Continuous Mesh Belt Furnaces with continuous load rate, atmosphere, hardening, tempering, and quench monitoring. Heat treatment of fasteners and fixings is a critical part of the manufacturing process. The control of temperature, time and atmosphere determines the quality, capability and reliability of the fastener. Fastener finished properties have complied with a targeted strength range.

Surface Treatment Process

(Zinc Plating Coating)

The electroplating process involves cleaning the fastener in an alkaline solution and removing rust with acid. Cleanliness is essential to ensure the adhesion of the coating. The fasteners are then dipped in a zinc-containing chemical bath for electro-deposition. DC current dissolves zinc at the anode, sending metal ions to the cathode to create a coating. Coating thickness varies with time, current, and bath chemistry.

Surface Treatment Process

(Zinc Flake Coating)
EBRO Fastener operates in Continuous Mesh Belt Furnaces with continuous load rate, atmosphere, hardening, tempering, and quench monitoring. Heat treatment of fasteners and fixings is a critical part of the manufacturing process. The control of temperature, time and atmosphere determines the quality, capability and reliability of the fastener. Fastener finished properties have complied with a targeted strength range.
The surface treatment can be seen as encapsulating the metal in a protective shell. In this way, the metal will not come into contact with oxygen and moisture, thus inhibiting the corrosion process. In this protection, friction control and appearance are also added. The protection is usually cathodic, meaning that it consists of a metal with a lower electron potential and will, therefore, be consumed before the base material in a corrosive environment.
Applying surface treatment is a complicated process that can involve up to 50 different steps. However, the process can be divided into three main stages:
Pre-treatment : Cleaning and activation of the surface which is to be coated.
Treatment : Application of base coat for corrosion protection.
After-treatment : Application of top-coat for extra protection, friction control, and appearance.
Although surface treatment has many essential features and can consist of several layers, it is surprisingly thin, only a few μm – Thinner than a human hair.
This comprehensive range of coatings technologies helps to streamline the coatings process, increase application efficiencies and deliver benefits that include reducing solvent use, increasing corrosion protection performance, achieving consistent color coverage and reducing sludge.
Limitless possibilities for every application. Boundless innovations for each market.
Together, we can change what's possible.
NOTE:
Plating: All the products, unless otherwise ordered, are supplied with a world-class manganese finish with a coat of rust preventive oil. No guarantee can be given for EBRO products that are plated by users or by outside plates, who may not have considered hydrogen embrittlement problems.

Effluent Treatment Plant (ETP)

We have a 100% fully functional ETP (Effluent Treatment Plant) is a process design for treating industrial wastewater for its reuse or safe disposal to the environment.

  • Influent : Untreated industrial waste water.
  • Effluent : Treated industrial waste water.
  • Sludge : Solid part separated from waste water by ETP.

Effluent treatment plant cleans industrial effluents, contaminated water from outlet pipes, etc. and reclaim the water resource for using in different purposes. Whenever there is a chance of extreme water contamination. These treatments are applied depending on many aspects or characteristics of the waste water and available space or location of the plants.

Why is ETP Required?

  • To clean industry effluent and recycle it for further use.
  • To reduce the usage of fresh/potable water in Industries.
  • To cut expenditure on water procurement.
  • To meet the Standards for the emission or discharge of environmental pollutants from various Industries set by the Government and avoid hefty penalties.
  • To safeguard the environment against pollution and contribute to sustainable development.

Broadly, the industrial process is having a negative influence on the environment. Pollution from inappropriate industrial wastewater treatment is a major environmental concern in India, particularly in the country's burgeoning small-scale manufacturing sector. Adoption of cleaner manufacturing technologies and waste reduction techniques is gaining popularity as a means of reducing industrial pollution discharge. Effluent Treatment Plants (ETPs) are one of the wastewater treatment options available to small and medium-sized industries.